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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Transit 2000.5 (01.2000-05.2006)

Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel - Cylinder Head Transit 2000.5 (01/2000-05/2006)
In-vehicle Repair

Special Tool(s)

Dial Indicator Gauge (Metric)

205-069 (15-046)

Holding Fixture, Dial Indicator Gauge

205-070 (15-022A)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

Holding Fixture, Dial Indicator Gauge

303-432 (21-183)

Socket, Fuel Injector Remove/Install

303-677 (21-236)

Aligner, Fuel Injector

303-711 (21-258)
Materials
Name
Specification
Loctite 7070
 

Removal

  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Remove the exhaust manifold.
    For additional information, refer to Exhaust Manifold in this section.
  1. Remove the generator. For additional information, refer to Section  414-02 Generator and Regulator.

  1. Remove the accessory drive belt tensioner bracket.

  1. Disconnect the cylinder head temperature (CHT) sensor electrical connector.

  1. Disconnect the degas hose from the thermostat housing.
  1. Remove the camshafts.
    For additional information, refer to Camshafts in this section.

  1. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.

  1. Disconnect the vacuum line from the EGR valve.

  1. Disconnect the EGR valve tube from the turbocharger.

  1. Detach the exhaust manifold to EGR valve tube from the exhaust manifold.

  1. Detach the EGR valve and exhaust manifold to EGR valve tube assembly from the engine lifting eye.

  1. NOTE:
    NOTE:The fuel injector locking sleeves must be fully loosened in order to remove the fuel injectors.
    Loosen the fuel injector locking sleeves and remove the fuel injectors by gently working them loose.

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head.
    • Discard the gasket and the bolts.

Installation

  1. Clean the mating faces of the cylinder head and cylinder block with Loctite 7070.
  1. Check the cylinder head for distortion. For additional information, refer to Section  303-00 Engine System - General Information.

  1. NOTE:
    NOTE:Measure the piston protrusion of each cylinder at top dead center (TDC).
    Measure the distance between the piston crown and the cylinder block at the points indicated.

  1. NOTE:
    NOTE:The largest measurement determines the choice of the cylinder head gasket.
    Using the special tools, measure the piston protrusion.
  1. Determine the cylinder head gasket.
    For additional information, refer to Specification - in this section.

  1. CAUTION:
    CAUTION:Install new cylinder head bolts.
    Install the cylinder head.
    • Tighten the bolts in the sequence shown in eight stages.
    • Stage 1: Tighten bolts 1 through 10 to 10 Nm.
    • Stage 2: Tighten bolts 11 through 18 to 5 Nm.
    • Stage 3: Tighten bolts 1 through 10 to 20 Nm
    • Stage 4: Tighten bolts 11 through 18 to 10 Nm.
    • Stage 5: Tighten bolts 1 through 10 to 40 Nm.
    • Stage 6: Tighten bolts 11 through 18 to 20 Nm.
    • Stage 7: Tighten bolts 1 through 10 to 180 degrees.
    • Stage 8: Tighten bolts 11 through 18 to 180 degrees.

  1. Using the special tools, install the fuel injectors.

  1. Attach the EGR valve and exhaust manifold to EGR valve tube assembly to the engine lifting eye.

  1. Attach the exhaust manifold to EGR valve tube to the exhaust manifold.

  1. Connect the EGR valve tube to the turbocharger.

  1. Connect the vacuum line to the EGR valve.

  1. Connect the EGR valve electrical connector.
  1. Install the camshafts.
    For additional information, refer to Camshafts in this section.

  1. Connect the degas hose to the thermostat housing.

  1. Connect the CHT sensor electrical connector.

  1. Install the accessory drive belt tensioner bracket.
  1. Install the generator. For additional information, refer to Section  414-02 Generator and Regulator.
  1. Install the exhaust manifold.
    For additional information, refer to Exhaust Manifold in this section.
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

In-vehicle Repair|Oil Pan > < Exhaust Manifold